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INSTALLATION To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a) Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a) 1. Disconnect the negative battery cable (-) following the instructions in the owner’s manual. 2. Locate the two-sided template (part number 50002-01) printed on a 11 x 17 inch sheet of poster board. Cut out the template as indicated. 3. If the motorcycle is radio equipped, separate the antenna cable from terminal at antenna base. Remove the nut, lockwasher and ground ring terminal from antenna terminal. Remove phillips head screw threaded into antenna base. Remove mast and antenna base. Detach mast from antenna base by turning counterclockwise with adjustable wrench across flats. 4. See Figure 10. Shield threads of antenna terminal stud with strip of light cardboard. Remove terminal with pliers across cardboard strip. Save terminal and mast for later installation. 5. See Figure 1. Open Tour-Pak top and remove all loose contents. Remove Tour-Pak. Align the template as follows: a. Place center line template (4) along rear top edge of Tour-Pak (1) with curved end against one corner. b. Mark centerline at top edge of Tour-Pak. c. Reverse center line template and mark center with curved end against opposite corner. d. If centerlines overlap, mark center one half the distance between the two lines. e. Place a square against lip at top of Tour-Pak and draw a 3 in (76 mm) line down from the center mark

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1 To remove your stock lever, use a 19mm wrench or (adjustable wrench) to remove the large sheet metal nut attached to the main pivot bolt that holds the lever. (Photo 1a) Once the locknut is removed, push the main pivot bolt out with your finger or if necessary tap lightly with a rubber mallet or plastic handle end of a screwdriver (Photo 1b) After the pivot bolt is removed, the lever will detach from the master cylinder. (Photo 1c) 1a See other side for further instructions INSTALLATION INSTRUCTIONS FOR PART # CRC552 ® C/5 Sport Clutch Lever Part # CRC552 1b 1c INSTRUCTIONS_CRC552 12/27/07 10:05 AM 23 4 2 Included with your ASV lever is a plastic bag that contains a custom pivot bolt, spacer & locknut. These parts will replace the OEM Brembo parts that were used with your stock lever. 3 Carefully place the lever into the master cylinder while aligning the plunger rod into the plunger cup on your ASV lever as shown in photo 3. 4 Align the lever and the master cylinder pivot bolt holes and Install the main pivot bolt, you will need to pre-load the lever into the master cylinder to get the bolt through the holes. The bolt head has two cut outs on the sides that need to be aligned with the matching area on the master cylinder. Be sure the head of the bolt seats down into the slotted area of the master cylinder. It may be necessary to use a rubber mallet or Plastic end of a screwdriver (Photo 4) to tap the head of the bolt down into its slot. 5 On the other side of the pivot bolt where the threads are, you will see that there is space around the pivot bolt. You will need to install the aluminum spacer that was supplied in the plastic bag with the pivot bolt and locknut. The spacer has a small flange on one side. The flange should be on the outer side when installing it into the hole surrounding the bolt. (Photo 5a) You may need to use pressure to seat the spacer fully into the hole surrounding the pivot bolt. You should be able to do this by using your fingers or thumbs as shown in photo 5b.

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1. Remove stock pushrods using a bolt cutter. 2. Place the motorcycle on a hydraulic center stand with the rear wheel raised off the ground. Remove spark plugs. CAUTION 1 WARNING 1 WARNING CAUTION 1 WARNING CAUTION ® i02097.tif Figure 1. Adjustable Push Rod Kit Number 17997-99A Pushrod Tube Adjusting Screw Flats Adjusting Screw Locknut 1 of 2 Exhaust Pushrod Tube has Thicker “Finished” area and is slightly longer Intake Pushrod Tube has Thinner “Finished” area and is slightly shorter 3. With transmission in gear use rear wheel to turn engine over until both front cylinder tappets are at their lowest point. 4. Replace O-rings, lower pushrod cover and spring cover keeper with new components supplied in kit. 5. See Figure 1. Loosen locknut on all of the pushrods and adjust them to their shortest length. NOTE See Figure 1. In Step 6, pushrods with the Thinner “Finished” area on the tubes must be installed to the Intake location on the cylinders; pushrods with the Thicker “Finished” area on the tubes are slightly longer and must be installed to the Exhaust locations on the cylinders. 6. Install pushrods with pushrod covers. Be sure adjuster end of pushrod is down and ball end of adjuster is in tappet socket. 7. If hydraulic tappets are used, adjust pushrods following procedure A. With solid tappets, follow procedure B. NOTE Pushrod adjustment must be made with engine cold. PROCEDUREA (Hydraulic Tappets) 1A. Adjust pushrod length to zero clearance. 2A. See Figure 1. With the pushrod tube kept from rotating with a 1/2 inch or adjustable wrench, slowly turn the adjusting screw with a 5/16 in. wrench, 2-1/2 complete turns counter clockwise (lengthening the pushrod) as viewed from the bottom. (You may wish to mark adjuster to aid in counting turns.) 3A. Hold adjusting screw and tighten locknut with 1/2 in. open end wrench against the pushrod tube. If pushrod turns with locknut use three open end wrenches, one to hold the pushrod tube, one to hold adjusting screw and one to turn locknut.